Infusion pump system and method

ABSTRACT

Some embodiments of an infusion pump system may be configured to provide a desired level of resistance to liquid ingress to the pump casing while contemporaneously providing air transmissibility for equalization of air pressure differentials between the interior and exterior of the pump casing. Further, some embodiments can detect when moisture inside a casing of the infusion pump system is greater than or equal to a threshold level and can initiate one or more patient safety countermeasures.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No. 13/908,616 filed Jun. 3, 2013, the entire disclosures of these prior related applications being incorporated herein by reference.

TECHNICAL FIELD

This document relates to an infusion pump system, such as a portable infusion pump system for dispensing a medicine.

BACKGROUND

Pump devices are commonly used to deliver one or more fluids to a targeted individual. For example, a medical infusion pump device may be used to deliver a medicine to a patient as part of a medical treatment. The medicine that is delivered by the infusion pump device can depend on the condition of the patient and the desired treatment plan. For example, infusion pump devices have been used to deliver insulin to the vasculature of diabetes patients so as to regulate blood-glucose levels.

Infusion pump devices often need to deliver medicine in accurately controlled dosages. Over-dosages and under-dosages of medicine can be detrimental to patients. For example, an infusion pump device that delivers an over-dosage or under-dosage of insulin to a diabetes patient can significantly affect the blood-glucose level of the patient.

In some circumstances, the ability of an infusion pump to deliver an accurately controlled dosage can be negatively affected if the pump device has experienced moisture ingress. For example, an infusion pump device may be damaged by moisture within the pump casing as a result of submersion in water or other water exposure over a particular period of time. Infusion pump casings can be sealed to protect against moisture ingress. However, completely sealing a pump casing in an airtight condition can result in air pressure differentials between the interior and exterior of the pump casing in some circumstances, such as when a user of an infusion pump travels in an airplane. In such circumstances, the pressure differential between the interior and the exterior of the infusion pump can cause unintended dispensation of the medicine or other medicine delivery errors.

SUMMARY

Some embodiments of an infusion pump system may be configured to provide a desired level of resistance to liquid ingress to the pump casing while contemporaneously providing air transmissibility for equalization of air pressure differentials between the interior and exterior of the pump casing. Further, some embodiments can detect when moisture inside a casing of the infusion pump system is greater than or equal to a threshold level and can initiate one or more patient safety countermeasures. In some circumstances, the patient safety counter measures can include, for example, one or more of disabling medicine delivery by the pump device, emitting an alarm to the user, and prompting the user to perform a number of remedial actions. The implementation of such features can help to enable an infusion pump system to be durable and to perform as intended, even when exposed to a variety of ambient conditions.

In some embodiments described herein, a portable infusion pump system may include a pump device and a controller device. The pump device may include a pump housing that defines a space to receive a medicine. The pump device may also include a drive system positioned in the pump housing to dispense the medicine from the pump device when the medicine is received in the space of the pump housing. The pump device may optionally include a structure positioned in the pump housing that defines an open airflow passageway so dimensioned to inhibit ingress of liquid to an interior of the pump housing and provide air pressure equilibrium between an exterior of the pump housing and the interior of the pump housing. Optionally, the controller device may be removably attachable to the pump housing so as to electrically connect with the pump device. The controller device may house control circuitry configured to communicate with the drive system positioned in the pump housing to control dispensation of the medicine from the pump device.

In particular embodiments, a medical infusion pump system may include a portable housing defining a space to receive a medicine. The system may also include a pump drive system to dispense medicine from the portable housing when the medicine is received in the space. The system may further include control circuitry that electrically communicates with the pump drive system to control dispensation of the medicine from the portable housing when the medicine is received in the space. The system may optionally include a liquid ingress resistance structure positioned in the portable housing. The liquid ingress resistance may be exposed to both an exterior of the portable housing and an interior of the portable housing. Also, the liquid ingress resistance structure may optionally define a predefined airflow passageway that provides air pressure equilibrium between the exterior of the portable housing and the interior of the portable housing and that inhibits ingress of water to the interior of the portable housing when the portable housing is submerged in water for a period of time.

Some embodiments described herein may include a method of operating a portable infusion pump system. The method may include dispensing a medicine from a reservoir positioned in a pump housing of a portable infusion pump system. The method may also include providing air pressure equilibrium between an exterior of a pump housing of a portable infusion pump system and an interior of the pump housing of the portable infusion pump system. Optionally, the air pressure equilibrium is provided via an airflow passageway defined by a structure positioned in the pump housing and exposed to both the exterior of the pump housing and the interior of the pump housing. The airflow passageway of the structure positioned in the pump housing may be optionally configured to inhibit ingress of water to the interior of the pump housing when the pump housing is submerged in water for a period of time.

Some or all of the embodiments described herein may provide one or more of the following advantages. First, some embodiments of the infusion pump system may be configured to resist liquid ingress and thereby protect the internal components housed inside the pump casing from damage by liquid contamination. Second, certain embodiments of the infusion pump system may be configured to allow air pressure equalization between the interior and exterior of the pump casing thereby mitigating unintended dispensations of medicine caused by ambient air pressure changes. Third, some embodiments of the infusion pump system may be configured to detect when the pump system has a moisture level inside a casing (e.g., an internal moisture level) that could potentially damage the system or cause an over-dosage or under-dosage of medicine to the user. Fourth, some embodiments of the infusion pump system may initiate user safety countermeasures upon detection that the system has an internal moisture level that is greater than or equal to a threshold level. Fifth, the infusion pump system may be configured to be portable, wearable, and (in some circumstances) concealable. For example, a user can conveniently wear the infusion pump system on the user's skin under clothing or can carry the pump system in the user's pocket (or other portable location) while receiving the medicine dispensed from the pump device.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded perspective view of an infusion pump system in accordance with some embodiments.

FIG. 2 is a perspective view of the infusion pump system of FIG. 1 in a detached state.

FIG. 3 is a perspective view of an infusion pump system, in accordance with some embodiments.

FIGS. 4-5 are perspective views of the pump device of FIGS. 1-2 being discarded and the controller device of FIGS. 1-2 being reused with a new pump device.

FIG. 6 is an exploded perspective view of a controller device for an infusion pump system, in accordance with some embodiments.

FIG. 7 is an exploded perspective view of a pump device for an infusion pump system, in accordance with some embodiments.

FIGS. 8A and 8B are perspective and cross-sectional views of an example liquid ingress tube for an infusion pump system, in accordance with some embodiments.

FIG. 9 is a schematic of moisture detection system, in accordance with some embodiments.

FIG. 10 is a flowchart describing a process of using a moisture detection system of an infusion pump system in accordance with some embodiments.

FIG. 11 is a perspective view of an alternative infusion pump system in accordance with some embodiments.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, an infusion pump system 10 can include a pump device 100 and a controller device 200 that communicates with the pump device 100. The pump device 100 in this embodiment includes a housing structure 110 that defines a cavity 116 in which a fluid cartridge 120 can be received. The pump device 100 also can include a cap device 130 to retain the fluid cartridge 120 in the cavity 116 of the housing structure 110. The pump device 100 can include a drive system that advances a plunger 125 in the fluid cartridge 120 so as to dispense fluid 126 therefrom.

In some embodiments, the controller device 200 communicates with the pump device 100 to control the operation of the drive system. When the controller device 200, the pump device 100 (including the cap device 130), and the fluid cartridge 120 are assembled together, the user can (in some embodiments) conveniently wear the infusion pump system 10 on the user's skin under clothing, in a pouch clipped at the waist (e.g., similar to a cell phone pouch), or in the user's pocket while receiving the fluid dispensed from the pump device 100. Optionally, the controller device 200 may be configured as a reusable component that provides electronics and a user interface to control the operation of the pump device 100. In such circumstances, the pump device 100 can be a disposable component that is disposed of after a single use. For example, as described in more detail below in connection with FIGS. 4-5, the pump device 100 can be a “one time use” component that is thrown away after the fluid cartridge 120 therein is exhausted. Thereafter, the user can removably attach a new pump device 100′ (having a new medicine cartridge 120′) to the reusable controller device 200 for the dispensation of fluid from a new fluid cartridge 120′. Accordingly, the user is permitted to reuse the controller device 200 (which may include complex or valuable electronics, as well as a rechargeable battery) while disposing of the relatively low-cost pump device 100 after each use. Such a pump system 10 can provide enhanced user safety as a new pump device 100′ (and drive system therein) is employed with each new fluid cartridge 120′.

Briefly, in use, the pump device 100 is configured to removably attach to the controller device 200 in a manner that provides a secure fitting, an overall compact size, and a reliable electrical connection that is resistant to water migration. For example, as described in more detail below in connection with FIGS. 1-5, the controller device 200 can include a housing 210 having a number of features that mate with complementary features of the pump housing 110. In such circumstances, the controller device 200 can removably attach with the pump device 100 in a generally side-by-side configuration. The compact size permits the infusion pump system 10 to be discrete and portable (as described below in connection with FIG. 3). Moreover, at least one of the pump device 100 or the controller device 200 can include a release member that facilitates an easy-to-use detachment and replacement process.

As described in more detail below in connection with FIGS. 7-9, some embodiments of the infusion pump system 10 can be configured to resist liquid ingress. For example, in some embodiments, each of the pump housing 110 and the controller device housing 210 is mechanically sealed against liquid intrusion (e.g., the pump housing 110 being sealed when the cap device 130 is attached) even when the system 10 is submerged underwater for a period of time, yet one or both of the pump housing 110 and controller housing 210 can be equipped with structure defining an airflow path to provide air transmissibility with the surrounding environment during use. In such embodiments, one or both of the housings 110 and 210 can be highly resistant to liquid ingress while simultaneously providing a predefined, open airflow pathway for the purposes of providing pressure equilibrium between the interior spaces of the respective housing 110 or 210 and the surrounding environment. What's more, as described further in reference to FIG. 2, in various implementations the pump device 100 and the controller device 200 can be mounted to one another using a sealed electrical connector assembly 118 and 218. Such a configuration can also provide water-resistant protection for the electrical connection between the pump device 100 and the controller device 200. Thus, using such components and sealing techniques the pump system 10 may be configured to resist damage caused by exposure to liquids.

Still referring to FIG. 1, while sealing the pump housing 110 and the controller housing 210 to inhibit liquid ingress provides advantageous protection against liquid contamination of the internal components housed therein, the aforementioned embodiments also achieve an air pressure balance between in the interior and exterior of the respective housing 110 or 210. For example, when airflow between in the interior and exterior of an infusion pump housing is substantially inhibited (e.g., the pump housing is sealed in a completely airtight condition), differentials between the interior pressure P_(i) and exterior pressure P_(e) of the infusion pump housing can arise in some circumstances. As described herein, some embodiments of the infusion pump system 10, while being resistant to liquid ingress, are configured to allow the transmission of air by which the interior pressure P_(i) of the pump housing 110 can be equalized with the ambient air pressure P_(e). Thus, those embodiments of the infusion pump system 10 can reduce the likelihood of unintended dispensations of medicine due to situations when the ambient air pressure P_(e) substantially changes, such as when a user of the infusion pump system 10 travels in an airplane.

In the particular embodiment depicted in FIG. 1, the example infusion pump system 10 includes an ingress tube 384 located in the pump device 100. In general, the ingress tube 384 is an elongate tube with a small interior passageway (as described in more detail in connection with FIGS. 7-9) that is so dimensioned to permit air to flow therethrough during normal operation while also preventing ingress of liquid even when the pump device 100 is submerged for a period of time (e.g., submerged in water at a depth of 1 meter for a period of about 1 minute or greater, about 1 minute to about 180 minutes, about 30 minutes to about 120 minutes, and preferably for a minimum period of about 30 minutes or greater). In this embodiment, the longitudinal length of the tube 384 is greater than the lateral width of the tube 384 (e.g., in this embodiment, multiple times greater than the lateral width of the tube 384). One end of the ingress tube 384 is openly exposed on the exterior of the pump housing 110 so as to be in fluid communication with the ambient conditions. The other end of the ingress tube 384 is open within the interior of the pump housing 110 and is in fluid communication with the interior of the pump housing 110.

The passageway of the ingress tube 384 can be sized to realize a desired balance between the competing objectives of preventing liquid ingress while allowing air transmission. In other words, the passageway of the ingress tube 384 can be sized large enough so as to accommodate an airflow rate between the interior and exterior of the pump housing 110 that can mitigate a potential for unintended dispensations of medicine owing to ambient air pressure changes. Furthermore, the passageway of the ingress tube 384 can be sized small enough to provide a desired level of liquid ingress protection. Here, the tube 384 provides a structure that defines an airflow path sized and shaped to achieve the desirable balance between the competing objectives of preventing liquid ingress while allowing air transmission, which in this embodiment is achieved at least in part due to the facts that liquid molecules are generally physically larger than gas molecules and that liquids generally have greater surface tension than gases.

In the embodiment shown in FIG. 1, the interior opening of the passageway defined by the ingress tube 384 is positioned adjacent to a moisture detector 380 arranged inside the housing structure 110 of the pump device 100. In particular embodiments of the infusion pump system 10, a second moisture detection system can be located within the controller housing structure 210, in addition to the moisture detector 380 within the pump device 100. The moisture detector 380 can be advantageous because in some situations, despite being resistant to liquid ingress, the pump device 100 may experience a liquid ingress through the ingress tube 384. This could happen, for example, in situations such as when the pump device 100 is submerged in liquid at a particular threshold depth or greater and for a particular threshold duration of time. In another example scenario, if the housing structure 110 has been damaged thereby compromising the housing's seal resistance to water migration, water could potentially seep into the housing structure 110 from sources such as rain, water splashes, and the like and be detected by the moisture detector 380.

The moisture detector 380 can be configured to sense if the pump device 100 has an internal moisture level that is greater than or equal to a threshold level. The threshold level can be established below the moisture level that could cause the pump device 100 to potentially malfunction. In that manner, the moisture detector 380 can be used to detect a potentially detrimental moisture level and to disable further operations of the potentially malfunctioning pump device 100 in a proactive manner. Such malfunctions might include an error to the pump drive system that causes the delivery of an over-dosage or under-dosage of medicine to the user, or a complete failure of the pump device 100 to operate.

As described in more detail below in connection with FIGS. 2 and 9, when the pump device 100 and the controller device 200 are electrically coupled, the moisture detector 380 can be in electrical communication with control circuitry housed in the controller device 200. In the illustrated embodiments, the electrical coupling can result from mechanical engagement between the pump device 100 and the controller device 200. In alternative embodiments, wireless electrical communications may be established between the pump device 100 and the controller device 200 (or functional equivalents thereto) with or without mechanical engagement or a direct electrical connection.

In response to the initial establishment of electrical communications between the pump device 100 and the controller device 200, the circuit housed in the controller device 200 can interrogate the moisture detector 380 to ascertain whether a high moisture level exists within the pump device 100. If a high moisture level is determined to be present, the controller device 200 can initiate appropriate user safety countermeasures. If a high moisture level is not detected, the pump system 10 can proceed with normal operations. During normal operations, the control circuitry housed in the controller device 200 can continue to periodically interrogate the moisture detector 380 at regular intervals, and if it is subsequently determined that a high moisture level is present the controller device 200 can respond by initiating appropriate user safety countermeasures.

Referring again to FIG. 1, the pump system 10 can be a medical infusion pump system that is configured to controllably dispense a medicine from the cartridge 120. As such, the fluid cartridge 120 can contain a medicine 126 to be infused into the tissue or vasculature of a targeted individual, such as a human or animal patient. For example, the pump device 100 can be adapted to receive a medicine cartridge 120 in the form of a carpule that is preloaded with insulin or another medicine for use in the treatment of Diabetes (e.g., Byetta®, Symlin®, or others). Such a cartridge 120 may be supplied, for example, by Eli Lilly and Co. of Indianapolis, Ind. Other examples of medicines that can be contained in the fluid cartridge 120 include: pain relief drugs, hormone therapy, blood pressure treatments, anti-emetics, osteoporosis treatments, or other injectable medicines. The fluid cartridge 120 may have other configurations. For example, the fluid cartridge 120 may comprise a reservoir that is integral with the pump housing structure 110 (e.g., the fluid cartridge 120 can be defined by one or more walls of the pump housing structure 110 that surround a plunger to define a reservoir in which the medicine is injected or otherwise received).

In some embodiments, the pump device 100 can include one or more structures that interfere with the removal of the medicine cartridge 120 after the medicine cartridge 120 is inserted into the cavity 116. For example, the pump housing structure 110 can include one or more retainer wings (not shown in FIG. 1) that at least partially extend into the cavity 116 to engage a portion of the medicine cartridge 120 when the medicine cartridge 120 is installed therein. Such a configuration may facilitate the “one-time-use” feature of the pump device 100. In some embodiments, the retainer wings can interfere with attempts to remove the medicine cartridge 120 from the pump device 100, thus ensuring that the pump device 100 will be discarded along with the medicine cartridge 120 after the medicine cartridge 120 is emptied, expired, or otherwise exhausted. In another example, the cap device 130 can be configured to irreversible attach to the pump body 110 so as to cover the opening of the cavity 116. For example, a head structure of the cap device 130 can be configured to turn so as to threadably engage the cap device 130 with a mating structure along an inner wall of the cavity 116, but the head structure may prevent the cap device from turning in the reverse direction so as to disengage the threads. Accordingly, the pump device 100 can operate in a tamper-resistant and safe manner because the pump device 100 can be designed with a predetermined life expectancy (e.g., the “one-time-use” feature in which the pump device is discarded after the medicine cartridge 120 is emptied, expired, or otherwise exhausted).

Still referring to FIG. 1, the controller device 200 can be removably attached to the pump device 100 so that the two components are mechanically mounted to one another in a fixed relationship. Such a mechanical mounting can form an electrical connection between the removable controller device 200 and the pump device 100. For example, the controller device 200 can be in electrical communication with a portion of a drive system (not shown in FIG. 1) of the pump device 100. As described in more detail below, the pump device 100 can include a drive system that causes controlled dispensation of the medicine or other fluid from the cartridge 120. In some embodiments, the drive system incrementally advances a piston rod (not shown in FIG. 1) longitudinally into the cartridge 120 so that the fluid is forced out of an output end 122. A septum 121 (FIG. 1) at the output end 122 of the fluid cartridge 120 can be pierced to permit fluid outflow when the cap device 130 is connected to the pump housing structure 110. For example, the cap device 130 may include a penetration needle that punctures the septum 121 during attachment of the cap device to the housing structure 110. Thus, when the pump device 100 and the controller device 200 are attached and thereby electrically connected, the controller device 200 communicates electronic control signals via a hardwire-connection (e.g., electrical contacts or the like) to the drive system or other components of the pump device 100. In response to the electrical control signals from the controller device 200, the drive system of the pump device 100 causes medicine to incrementally dispense from the medicine cartridge 120. Power signals, such as signals from the rechargeable battery 245 (refer to FIG. 6) of the controller device 200 and from the power source 310 (refer to FIG. 7) of the pump device 100 may also be passed between the controller device 200 and the pump device 100.

As shown in FIG. 1, the pump device 100 can include an electrical connector 118 (e.g., having conductive pads, pins, and the like) that is exposed to the controller device 200 and that mates with a complementary electrical connector (refer to connector 218 in FIG. 2) on the adjacent face of the controller device 200. The electrical connectors 118 and 218 provide the electrical communication between the control circuitry (refer, for example, to FIG. 6) housed in the controller device 200 and at least a portion of the drive system or other components of the pump device 100. For example, in some embodiments, the electrical connectors 118 and 218 can permit the transmission of electrical control signals to the pump device 100 and the reception of feedback signals (e.g., sensor signals) from particular components within the pump device 100. The electrical connectors 118 and 218 may similarly facilitate transmission of one or more power signals from the rechargeable battery pack 245 to the pump device 100, where the signals may be used to provide power to components of the pump device 100, or to transmit one or more power signals from the power source 310 to the controller device, where the signals may be used to charge the rechargeable battery 245 or to power components of the controller device 200.

Still referring to FIG. 1, the controller device 200 can include a user interface 220 that permits a user to monitor the operation of the pump device 100. In some embodiments, the user interface 220 can include a display device 222 and one or more user-selectable buttons (e.g., several buttons 224 are shown in the embodiment of FIG. 1). The display device 222 can include an active area in which numerals, text, symbols, images, or a combination thereof can be displayed. For example, the display device 222 can be used to communicate a number of settings or menu options for the infusion pump system 10. In this embodiment, the user may press one or more of the buttons to shuffle through a number of menus or program screens that show particular settings and data (e.g., review data that shows the medicine dispensing rate, the total amount of medicine dispensed in a given time period, the amount of medicine scheduled to be dispensed at a particular time or date, the approximate amount of medicine remaining in the cartridge 120, or the like). In some embodiments, the user can adjust the settings or otherwise program the controller device 200 by pressing one or more buttons of the user interface 220. For example, in embodiments of the infusion pump system 10 configured to dispense insulin, the user may press one or more of the buttons to change the dispensation rate of insulin or to request that a bolus of insulin be dispensed immediately or at a scheduled, later time. In some implementations, the display device 222 may also be used to communicate information regarding remaining battery life.

Accordingly, when the controller device 200 is connected to the pump device 100, the user can be provided with the opportunity to readily monitor the infusion pump operation by simply viewing the user interface 220 of the controller device 200 connected to the pump device 100. Such monitoring capabilities may provide comfort to a user who may have urgent questions about the current operation of the pump device 100. Also, in these embodiments, there may be no need for the user to carry and operate a separate module to monitor the operation of the pump device 100, thereby simplifying the monitoring process and reducing the number of devices that must be carried by the user. If a need arises in which the user desires to monitor the operation of the pump device 100 or to adjust the settings of the pump system 10 (e.g., to request a bolus amount of medicine), the user can readily operate the user interface 220 of the controller device 200, which is removably attached to the pump device 100, without the requirement of locating and operating a separate monitoring module.

The controller device 200 can also be equipped with an inspection light device 230. The inspection light device 230 can provide the user with a tool to illuminate and inspect a targeted location. For example, the inspection light device 230 can be directed at the infusion site on the user's skin to verify that the infusion set is properly embedded, or the inspection light device 230 can be directed at the pump device 100 to illuminate the cavity 116 or other areas.

The inspection light device 230 can also be used to notify the user to an alert condition of the pump system 10. For example, as described further in reference to FIG. 9 below, the inspection light device 230 can be activated when the moisture detector has detected a moisture level greater than or equal to the threshold level. An activation of the inspection light device 230 can thereby provide a visual notification (as an alternative to, or in addition to, the visual notification provided on the display device 222) to the user that attention to the pump system 10 is warranted.

Referring now to FIG. 2, when the infusion pump system 10 operates, the controller device 200 can be removably attached to the pump device 100 in a side-by-side arrangement. For example, the pump device 100 may be moved in a longitudinal direction (e.g., refer to direction 219 in FIG. 4) toward the controller device 200 until the complementary features connect and secure the separate components in the side-by-side arrangement. The controller device 200 can include a controller housing structure 210 having a number of features that are configured to mate with complementary features of the pump housing structure 110 so as to form a releasable mechanical connection. For example, the pump housing structure 110 can include a barrel 111 that mates with a complementary barrel channel 211 of the controller housing 210. In various implementations, the pump device 100 and the controller device 200 can be mounted to one another so that the assembled system 10 is resistant to water migration both into the pump housing structure 110 and the controller housing structure 210. Such a configuration can also provide water-resistant protection for the electrical connection between the pump device 100 and the controller device 200. Thus, the sensitive internal components in the controller device 200 and the pump device 100 may be reliably protected from water migration if the user encounters some amount of water (e.g., rain, incidental splashing, and the like) while using the pump system 10. However, in the event of a more substantial exposure to water, such as a submersion over an extended period of time, the moisture detector 380 as described herein can protect the user from a pump system 10 malfunction that may result from water ingress into the pump housing 110 (or into the controller housing 210 if the controller device 200 is also equipped with a moisture detector similar to the detector 380 (FIG. 9)).

Referring to FIG. 3, the infusion pump system 10 can be configured to be portable and can be wearable and concealable. For example, a user can conveniently wear the infusion pump system 10 on the user's skin (e.g., skin adhesive) underneath the user's clothing or carry the pump device 100 in the user's pocket (or other portable location) while receiving the medicine dispensed from the pump device 100. The pump system 10 is shown in FIG. 3 as being held in a user's hand 5 so as to illustrate an exemplary size of the system 10 in accordance with some embodiments. This embodiment of the infusion pump system 10 is compact so that the user can wear the portable infusion pump system 10 (e.g., in the user's pocket, connected to a belt clip, adhered to the user's skin, or the like) without the need for carrying and operating a separate module. In such embodiments, the cap device 130 of the pump device 100 can be configured to mate with an infusion set 146. In general, the infusion set 146 can be a tubing system that connects the infusion pump system 10 to the tissue or vasculature of the user (e.g., to deliver medicine into the tissue or vasculature under the user's skin). The infusion set 146 can include a flexible tube 147 that extends from the pump device 100 to a subcutaneous cannula 149 that may be retained by a skin adhesive patch (not shown) that secures the subcutaneous cannula 149 to the infusion site. The skin adhesive patch can retain the infusion cannula 149 in fluid communication with the tissue or vasculature of the user so that the medicine dispensed through the tube 147 passes through the cannula 149 and into the user's body. The cap device 130 can provide fluid communication between the output end 122 (FIG. 1) of the medicine cartridge 120 and the tube 147 of the infusion set 146.

In some embodiments, the infusion pump system 10 can be pocket-sized so that the pump device 100 and controller device 200 can be worn in the user's pocket or in another portion of the user's clothing. In some circumstances, the user may desire to wear the pump system 10 in a more discrete manner. Accordingly, the user can pass the tube 147 from the pocket, under the user's clothing, and to the infusion site where the adhesive patch can be positioned. As such, the pump system 10 can be used to deliver medicine to the tissues or vasculature of the user in a portable, concealable, and discrete manner.

In some embodiments, the infusion pump system 10 can be configured to adhere to the user's skin directly at the location in which the skin is penetrated for medicine infusion. For example, a rear surface 102 (FIG. 2) of the pump device 100 can include a skin adhesive patch so that the pump device 100 can be physically adhered to the skin of the user at a particular location. In these embodiments, the cap device 130 can have a configuration in which medicine passes directly from the cap device 130 into an infusion cannula 149 that is penetrated into the user's skin. In some examples, the user can temporarily detach the controller device 200 (while the pump device 100 remains adhered to the skin) so as to view and interact with the user interface 220.

Referring now to FIGS. 4-5, the infusion pump system 10 can be operated such that the pump device 100 is a disposable, non-reusable component while the controller device 200 is a reusable component. In these circumstances, the pump device 100 may be configured as a “one-time-use” device that is discarded after the medicine cartridge is emptied, expired, or otherwise exhausted. Thus, in some embodiments, the pump device 100 can be designed to have an expected operational life of about 1 day to about 30 days, about 1 day to about 20 days, about 1 to about 14 days, or about 1 day to about 7 days—depending on the volume of medicine in the cartridge 120, the dispensation patterns that are selected for the individual user, and other factors. For example, a medicine cartridge 120 containing insulin can have an expected usage life of about 7 days after the cartridge is removed from a refrigerated state and the septum 121 is punctured. In some circumstances, the dispensation pattern selected by the user can cause the insulin to be emptied from the medicine cartridge 120 before the 7-day period. If the insulin is not emptied from the medicine cartridge 120 after the 7-day period, the remaining insulin can become expired sometime thereafter. In either case, the pump device 100 and the medicine cartridge 120 therein can be collectively discarded after exhaustion of the medicine cartridge 120 (e.g., after being emptied, expired, or otherwise not available for use).

The controller device 200, however, may be reused with subsequent new pump devices 100′ and new medicine cartridges 120′. As such, the control circuitry, the user interface components, the rechargeable battery pack 245, and other components that may have relatively higher manufacturing costs can be reused over a longer period of time. For example, in some embodiments, the controller device 200 can be designed to have an expected operational life of about 1 year to about 7 years, about 2 years to about 6 years, or about 3 years to about 5 years—depending on a number of factors including the usage conditions for the individual user. Accordingly, the user can be permitted to reuse the controller device 200 (which can include complex or valuable electronics, and a rechargeable battery pack) while disposing of the relatively low-cost pump device 100 after each use. Such a pump system 10 can provide enhanced user safety as a new pump device 100′ (and drive system therein) is employed with each new medicine cartridge 120′.

Referring to FIGS. 4-5, the same controller device 200 can be reused with a new pump device 100′ having a new medicine cartridge 120′ retained therein, and the previously used pump device 100, including the exhausted medicine cartridge, can be discarded in a discard bin 20. The new pump device 100′ (FIG. 4) can have a similar appearance, form factor, and operation as the previously used pump device 100, and thus the new pump device 100′ can be readily attached to the controller device 200 for controlled dispensation of medicine from the new medicine cartridge 120′. In some embodiments, the user can prepare the new pump device 100′ for use with the controller device 200. For example, the user may insert the new medicine cartridge 120′ in the cavity 116 of the new pump device 100′ and then join the cap device 130 to the pump housing to retain the new medicine cartridge 120′ therein (refer, for example, to FIG. 1). Although the tubing 147 of the infusion set 146 is not shown in FIG. 4, it should be understood that the tubing 147 can be attached to the cap device 130 prior to the cap device 130 being joined with the housing 110. For example, a new infusion set 146 can be connected to the cap device 130 so that the tubing 147 can be primed (e.g., a selected function of the pump device 100 controlled by the controller device 200) before attaching the cannula's adhesive patch to the user's skin. As shown in FIG. 4, the new medicine cartridge 120′ may be filled with medicine such that the plunger 125 is not viewable through the barrel 111.

The new pump device 100′ can be removably attached to the controller device 200 to assemble into the infusion pump system 10 for delivery of medicine to the user. As previously described, the guided motion in the longitudinal direction 219 provides the user with a convenient “one-movement” process to attach the pump device 100′ and the controller device 200. For example, the user can readily slide the pump device 100′ and the controller device 200 toward one another in a single movement (e.g., in the longitudinal direction 219) that causes both a physical connection and an electrical connection. Thus, the infusion pump system 10 can permit users to readily join the pump device 100′ and the controller device 200 without compound or otherwise difficult hand movements—a feature that can be particularly beneficial to child users or to elderly users.

Referring now to FIG. 6, the controller device 200 (shown in an exploded view) houses a number of components that can be reused with a series of successive pump devices 100. In particular, the controller device 200 can include controller circuitry 240 and a rechargeable battery pack 245, each arranged in the controller housing 210. As described above, rechargeable battery pack 245 may provide electrical energy to components of controller circuitry 240, other components of the controller device (e.g., a display device 222 and other user interface components, sensors, or the like), or to components of the pump device 100. Controller circuitry 240 may be configured to communicate control or power signals to the drive system of the pump device 100, or to receive power or feedback signals from the pump device 100.

In some embodiments, the controller device 200 can house a moisture detector (not shown) that is similar to the moisture detector 380 (FIG. 8) in the pump housing 110, which can be employed to detect high levels of moisture within the controller housing 210. If a moisture level at or above a threshold level is detected inside the controller housing 210, the infusion pump system 10 can initiate user safety countermeasures as described herein.

Still referring to FIG. 6, the user interface 220 of the controller device 200 can include input components and/or output components that are electrically connected to the controller circuitry 240. For example, the user interface 220 can include the display device 222 having an active area that outputs information to a user and buttons 224 that the user can use to provide input. Here, the display device 222 can be used to communicate a number of settings or menu options for the infusion pump system 10. In some embodiments, the controller circuitry 240 can receive input commands from a user's button selections and thereby cause the display device 222 to output a number of menus or program screens that show particular settings and data (e.g., review data that shows the medicine dispensing rate, the total amount of medicine dispensed in a given time period, the amount of medicine scheduled to be dispensed at a particular time or date, the approximate amount of medicine remaining the cartridge 120, the amount of battery life remaining, or the like). The controller circuitry 240 can be programmable to cause the controller circuitry 240 to change any one of a number of settings for the infusion pump system 10. For example, the user may provide one or more instructions to adjust a number of settings for the operation of the infusion pump system 10. Such settings may be stored in one or more memory devices arranged in the controller circuitry 240.

As shown in FIG. 6, the infusion pump system 10 can be equipped with the inspection light device 230 to conveniently aid in visual inspection processes. For example, visual inspection and possible change of the infusion set 146 may be required in less than optimal conditions, including low-light conditions. Likewise, visual inspection of the pump housing cavity 116 (and the medicine cartridge 120 therein) may be required in low-light conditions. The user interface 220 of the controller device 200 can include an illuminated display screen 222 to facilitate the user's view of the display screen 222, but the inspection light device 230 provides a dedicated light source for illuminating targeted sites external to the controller device 200, for providing an alert notification, or a combination thereof.

The inspection light device 230 can include one or more user triggered light sources that are positioned to direct illumination at targeted objects outside of the pump system 10 or at components of the pump device 100. In the embodiment depicted in FIG. 6, the light source is arranged on the controller device 200. Such an arrangement provides close proximity to the control circuitry 240 housed in the controller device 200, thereby permitting the light source of the inspection light device 230 to be electrically connected to the control circuitry. In other embodiments, could be arranged on the pump device 100 or on both the controller device 200 and the pump device 100.

The inspection light device 230 can also be used to provide a visual notification to the user in the event of an alert or alarm condition. For example, as described further in reference to FIG. 9, the inspection light device 230 can be activated in response to detection by the moisture detection system of a moisture level within the housing(s) of the pump system 10 that is at or above a threshold value at which a potential malfunction of the pump system 10 may be caused.

In some optional embodiments, the controller circuitry 240 can include a cable connector (e.g., a USB connection port or another data cable port) that is accessible on an external portion of the controller housing 210. As such, a cable can be connected to the controller circuitry 240 to upload data or program settings to the controller circuitry or to download data from the controller circuitry. For example, historical data of medicine delivery can be downloaded from the controller circuitry 240 (via the cable connector) to a computer system of a physician or a user for purposes of analysis and program adjustments. Optionally, the data cable can also provide recharging power.

Referring now to FIG. 7, the pump device 100 can include a drive system 300 that is controlled by the controller device 200. As described in more detail below, the drive system 300 can incrementally dispense fluid in a controlled manner from cartridge 120 inserted into the pump device 100. Also, the pump device 100 may include a connector circuit 318 to facilitate the transfer of signals to and from the electrical connector 118. In some implementations, the connector circuit 318 in the pump device 100 may include a memory device that can store data regarding the pump device 100 and its operational history. As previously described, the electrical connector 118 of the pump device 100 can mate with the connector 218 (FIG. 2) of the controller device 200 so that electrical communication can occur between the pump device 100 and the controller device 200. In some embodiments, the connector circuit 318 can operate as a passageway to transmit electrical control signals from the controller circuitry 240 of the controller device 200 to the drive system 300. The connector circuit 318 can also operate as a passageway for the electrical power from a power source 310 housed in the pump device 100 to pass to the controller device 200 for recharging of the rechargeable battery 245. Furthermore, the connector circuit 318 can operate as a passageway for feedback signals from the drive system 300 to the controller circuitry 240 of the controller device 200.

In this embodiment, the pump device 100 houses the drive system 300 and the power source 310. For example, the power source 310 may comprise an alkaline battery cell, such as a 1.5 Volt “AAA” alkaline battery cell, which is contained in a dedicated space of the pump housing structure 110. The power source 310 may be capable of transmitting electrical energy to the controller device 200 when the pump device 100 is attached to the controller device 200, via connectors 118 and 218 as described above. For example, the power source 310 may be used to charge the rechargeable battery pack 245 when the pump device 100 is attached to the controller device 200. In some embodiments, the power source 310 is used to provide energy to the drive system 300 of the pump device 100, and also to electronic components of the controller device 200. In particular embodiments, the power source 310 may provide the energy to power all aspects of the infusion pump system 10. In some alternative embodiments, the rechargeable battery 245 housed in the controller 200 may provide the energy to power all aspects of the infusion pump system 10. In other embodiments, the rechargeable battery 245 and the power source 310 may each be responsible for powering particular aspects of the infusion pump system 10. In further embodiments, the rechargeable battery 245 may provide the energy to supplement the energy provided by the power source 310 to power aspects of the infusion pump system.

Still referring to FIG. 7, in some embodiments, the drive system 300 may include a number of components, such as an electrically powered actuator (e.g., reversible motor 320 or the like), a drive wheel 360, a bearing 365, a flexible piston rod 370, a piston rod guide 363, and a plunger engagement device 375. In this embodiment, the reversible motor 320 drives a gear system (not shown in FIG. 7) to cause the rotation of the drive wheel 360 that is coupled with the bearing 365. The drive wheel 360 may include a central aperture with an internal thread pattern, which mates with an external thread pattern on the flexible piston rod 370. The interface of the threaded portions of the drive wheel 360 and flexible piston rod 370 may be used to transmit force from the drive wheel to the piston rod 370. Accordingly, in the embodiment of FIG. 7, the drive wheel 360 is the driver while the flexible piston rod 370 is the driven member. As further described below, the rotation of the drive wheel 360 can drive the flexible piston rod 370 forward in a linear longitudinal direction.

Referring now to FIGS. 7-9, the pump device 100 (or, in some embodiments, the controller device 200, or both devices 100 and 200) can be equipped with a structure that inhibits the ingress of liquids while also defining an open airflow path to provide air pressure equilibrium with the surrounding environment. For example, the pump device 100 (or, in some embodiments, the controller device 200, or both devices 100 and 200) can house the aforementioned ingress tube 384 and (optionally) a moisture detector 380 that is a part of a moisture detection system 379 (refer to FIG. 9). As previously described in connection with FIG. 1, a first end 385 of the ingress tube 384 is exposed to the ambient surroundings on the exterior of the pump housing 110. For example, the first end 385 can engage into or slightly through a clearance hole 112 in the pump housing 110. The interface between the outer diameter of the ingress tube 384 and the clearance hole 112 can be sealed to prevent fluid transmission therebetween. A second end 386 of the ingress tube 384 can be located within the pump housing 110 and located adjacent to an absorbent element 382 of the moisture detector 380. Further, in this particular embodiment, the open airflow path between the first and second open ends 385 and 386 can be vacant and free of occupying structures. Using this arrangement, any liquid that flows into the pump housing 110 through the ingress tube 384 will be absorbed by the absorbent element 382 of the moisture detector 380 so that the liquid can be detected by the moisture detection system 379.

The ingress tube 384 in this embodiment is an elongate tube with a central passageway that extends between the ends 385 and 386. The length and diameter of the ingress tube 384 passageway can be configured to resist the transmission of liquids through the passageway while still allowing an extent of air to flow through the passageway. To accomplish this, the diameter of the ingress tube 384 can be selected in accordance with the teachings herein, such that it is small enough to resist liquid transmissions while being large enough to allow some air transmission.

In the example embodiment provided, the ingress tube 384 includes a restriction region 387. The restriction region 387 is a portion of the ingress tube 384 in which the passageway has a smaller dimension as compared to other portions of the passageway in the tube 384. In some embodiments, two or more restriction regions can be included, which may or may not be of the same size. In alternative embodiments, the ingress tube 384 has a consistent diameter along the entire passageway of the ingress tube 384 with no such restriction regions.

In some embodiments, the restriction area 387 can be formed by a deformation of the ingress tube 384 such that the ingress tube 384 has a flattened area of the passageway 388 (best seen in FIG. 8B). Such a restriction area 387 can be the result of a compression, crimp, indentation, bend, constriction, occlusion, deformation, and the like. In alternative embodiments, the restriction areas can be other types of restrictions. For example, the restrictions can be created by including particular segments of the ingress tube that have precise orifices (such as those formed by lasers), valves (e.g., needle valves), sintered materials, and by using other suitable devices and techniques.

Referring to FIG. 8B, the flattened passageway 388 of the restriction region 387 has an elongate cross-sectional profile. The most restrictive geometric aspect of the flattened passageway 388 is the width W of the flattened passageway 388. The width W can be selected in accordance with the teachings herein to provide a desired degree of liquid flow restriction. In some embodiments, the average width W can be from about 10 to about 40 microns, about 10 to about 30 microns, about 7 to about 17 microns, about 9 to about 15 microns, and preferably about 11 to about 13 microns in this particular embodiment so as to provide a selected level of liquid flow restriction. In some embodiments, the average diameter of less restricted portions of the passageway defined by the ingress tube 384 can be from about 0.1 to 1.5 millimeters, about 0.2 to 1.0 millimeters, about 0.3 to 0.8 millimeters, and preferably about 0.4 to 0.7 millimeters in this particular embodiment.

While the ingress tube 394 is resistant to liquid flow, the inclusion of the moisture detection system 379 can be advantageous because in some situations the pump device 100 may nevertheless experience a liquid ingress through the ingress tube 384. This could happen, for example, in situations such as when the pump device 100 is submerged in liquid at a particular threshold depth or greater and for a particular threshold duration of time.

Referring to FIGS. 7 and 9, the moisture detection system 379 can detect a moisture level within the infusion pump system 10 that is greater than or equal to a moisture threshold level. The moisture threshold level can be established at or below the lowest level of moisture that may induce a malfunction of the infusion pump system 10. The moisture detection system 379 can thereby sense and forewarn the user of moisture levels that have the potential to induce damage to the infusion pump system 10, including the type of damage that could cause over-dosage or under-dosage of medicine to the user, in a proactive manner. In other words, when a moisture level at or above the threshold level is detected by the moisture detection system 379, the controller device 200 can initiate appropriate user safety countermeasures (some examples of such countermeasures are described in connection with FIG. 10).

In this embodiment, the example moisture detector 380 is an electrical resistance-type moisture sensor that utilizes the relationship between the moisture content of a generally insulative substance (absorbent element 382) and the electrical resistance of the insulative substance. When the insulative absorbent element 382 absorbs moisture, some electrical current can be conducted between the electrical connections, and that conductance of electricity can be detected by a monitoring circuit (FIG. 9). The amount of electricity conducted will be related to the amount of moisture in the insulative substance. Using these principles, an electrical resistance-type moisture sensor can be used to detect the presence of moisture at or above a threshold level amount of moisture within the infusion pump system 10.

A variety of types and configurations of moisture detectors are envisioned within the scope of this document. For example, in some embodiments, the moisture detector for the moisture detection system can include one or more electrochemical-based moisture sensor devices. Such electrochemical-based moisture sensor devices may in some cases be capable of distinguishing different types of moisture, such as water versus insulin (which could leak from a damaged insulin cartridge, for example). The infusion pump system 10 may in such cases be configured to provide the user with alarm messages that provide specific information as to the type of moisture detected (e.g., insulin, water, or some other type of moisture).

Still referring to FIGS. 7 and 9, the example moisture detection system 379 includes at least the moisture detector 380 and a detection software component of the controller circuitry 240. In this embodiment, the moisture detector 380 includes an absorbent element 382 and a circuit board 378 housed inside the pump housing 110. The absorbent element 382 can comprise one or more of a variety of materials. In general, the absorbent element 382 can be made from a suitable material that provides the characteristics of being electrically insulative (when dry) and liquid absorbent. For instance, the example moisture detector 380 includes an absorbent element 382 that is a foam material. A hydrophilic sponge material such as AQUAZONE® WD available from Foamex Innovations of Media, Pa. is one example of a suitable foam material. Other example materials are the medical foam materials from Rynel, Inc. of Wiscasset, Me.

In this embodiment, at least portions of the absorbent element 382 and the circuit board 378 are in physical contact with each other. For example, three conductive pads 396, 397, and 398 on the circuit board 378 are each in contact with portions of the absorbent element 382. The conductive pads 396, 397, and 398, being in contact with portions of the absorbent element 382, are thereby arranged to be in electrical communication with each other via conductance of electricity through the absorbent element 382. In some embodiments pins, probes, nodes, and the like are used as alternatives to the conductive pads 396, 397, and 398.

Some or all of the pads 396, 397, and 398 are individually in electrical communication with the controller circuitry 240. That is, in the embodiment shown in FIG. 9, the pads 396, 397, and 398 are hardwired (via the electrical connectors 118 and 218) to the controller circuitry 240. In alternative embodiments, some or all of the pads 396, 397, and 398 can be in wireless communication with the controller circuitry 240. By virtue of the electrical communication between the pads 396, 397, and 398 and the controller circuitry 240, the controller circuitry 240 can monitor the electrical status of the pads 396, 397, and 398. As described further below, by monitoring the electrical status of the pads 396 and 397 the controller circuitry 240 can ascertain whether or not a high moisture level exists within the pump device 100.

In addition to the connections from the pads 396, 397, and 398 to the controller circuitry 240, the pads 396, 397, and 398 may also connected to other points on the electrical systems within the pump device 100. For example, in some embodiments, pads 396 and 397 can be individually connected to separate voltage sources on the circuit board 378, and pad 398 is connected to ground 399 (common). In this example, when an electrical component (e.g., a pad or a voltage source) has an electrical charge, it can be said that the component is “high.” Conversely, when an electrical component does not have an electrical charge it can be said that the component is “low.” Hereafter, the terms “high” and “low” may be used to indicate an existence or absence of electrical potential in regards to the pads 396 and 397 and the voltage sources that are connected to the pads 396 and 397. In this particular example, the infusion pump system 10 may operate such that either one or both of the voltage sources that are connected to pads 396 and 397 are always high. That is, at least one pad 396 or 397 always receives an electrical potential from its respective voltage source when the infusion pump system 10 is in operation. In a first operative scenario, pad 396 receives electrical potential and pad 397 does not receive electrical potential. In a second operative scenario, pad 397 receives electrical potential and pad 396 does not receive electrical potential. In a third operative scenario, both pads 396 and 297 receive electrical potential. During operation of the infusion pump system 10, the electrical potential of the voltage sources connected to pads 396 and 397 can be switched between any of the aforementioned three scenarios. But at all times during normal operation of the infusion pump system 10, at least one of the voltage sources connected to pads 396 and 397 is high. In contrast, pad 398 is always low because pad 398 is electrically connected to ground 399.

Referring to FIG. 9, when pump device 100 is in the normal state, the absorbent element 382 is substantially dry or contains less than a threshold level amount of moisture. In that condition, little or substantially no electricity is conducted through the insulative absorbent element 382. Consequently, when pads 396 and 397 are supplied with an electrical potential, the pads 396 and 397 will maintain the electrical potential. That holds true because there is no conductive path for the electrical potential to flow away from the pads 396 and 397 when the absorbent element 382 contains less than a threshold level amount of moisture. Therefore, in this normal state, either one or both pads 396 and 397 will be high. The controller circuitry 240 will detect that at least one pad 396 or 397 is high, and the controller circuitry 240 will interpret the status of the pump device 100 as normal (as not having a high moisture level). Indeed, as long as the controller circuitry 240 detects that at least one of the pads 396 or 397 is high, the controller circuitry 240 will allow the normal operations of the infusion pump system 10 to continue.

However, when the absorbent element 382 absorbs moisture at a level that is greater than a threshold level amount of moisture, the electrical resistance of the absorbent element 382 is decreased, and the absorbent element 382 may then conduct electricity more readily. In this embodiment, the extent of the decrease in resistance of the absorbent element 382 is generally proportional to the amount of moisture absorbed by the absorbent element 382. This decrease in resistance of the absorbent element 382 enables the absorbent element 382 to effectively provide an electrical connection from pads 396 and 397 to pad 398 (ground), thereby causing both of the pads 397 and 397 to provide a low signal (e.g., connected to ground). The absorbent element 382 provides this type of conductive path between the pads 396, 397, and 398 when the absorbent element 382 receives at least a threshold level amount of moisture (e.g., such as a particular amount of moisture seeping into the pump housing via the ingress tube 384 (FIGS. 7 and 8A-B).

For the aforementioned reasons, when the absorbent element 382 has at least a threshold level amount of moisture content, both pads 396 and 397 will be low. Thus, when the detection software component of the controller circuitry 240 interrogates the moisture detector 380, it will in turn detect that both pads 396 and 397 are low. As a result of detecting that both pads 396 and 397 are low, the controller circuitry 240 will initiate one or more user safety countermeasures as described further herein.

Referring now to FIG. 10, a controller of an infusion pump system that includes a moisture detector can implement a process 400 of detecting a moisture event. Such a process 400, for example, can be implemented by the controller circuitry 240 in the controller device 200 of the infusion pump system 10 (FIG. 1). Alternatively, some operations of the process 400 could be implemented in an infusion pump device in which the controller and the pump drive system are integrated into a single housing (such as the embodiment of FIG. 11).

In operation 410, the controller circuitry can receive an electrical signal indicating that a pump device is in electrical communication (hard wired or wirelessly) with the controller device. For example, in the embodiments in which controller device 200 is separately housed from the pump device 100, the two components can be electrically connected via the connectors 118 and 218. As such, the signal can be a voltage from power source 310 that is detected by controller circuitry 240 when the pump device 100 is electrically connected to the controller device 200.

In operation 412, the controller circuitry monitors the status of the moisture detector. Such a monitoring operation can include periodic samplings of the moisture detector by the controller circuitry. For example, in the embodiments described above, the controller circuitry 240 may sample the moisture detector 380 prior to each time the controller circuitry 240 initiates a dispensation of medicine from the infusion pump system 10. In other embodiments, the controller circuitry 240 may sample the moisture detector 380 on a periodic time basis, such as about every 1, 2, 5, or 10 minutes, for example. If the moisture detection circuit indicates that the pump system is in a “high moisture level” mode, the monitoring operation 412 will detect that the signal(s) from the moisture detector differ from the signal(s) when in the “normal” mode.

In operation 414, the controller device determines if the moisture detector indicates a moisture level greater than or equal to a threshold level. For example, in the embodiment shown in FIGS. 7 and 9, the moisture detector 380 can indicate the presence of excessive moisture in the absorbent element 382, thereby causing the moisture detection system 379 to ascertain the “high moisture level” detected mode. If the moisture detector does not indicate that a high moisture level event occurred, the process 400 returns to the monitoring operation 412.

Still referring to FIG. 10, if the moisture detector indicates a moisture level greater than or equal to a threshold level, the controller device can respond according to some or all of the operations 416, 418, 420, 422, 424, and 426.

In operation 416, in response to the controller device's determination that the moisture detector system indicates the pump device 100 has an internal moisture level at or above the moisture threshold level (e.g., the “high moisture level” mode has been sensed), the controller device can act to disable the pump drive system. For purposes of safety, the pump system 10 may immediately stop the delivery of medicine to the user of the system. As described above, the cessation of medicine delivery can be an appropriate user safety precaution because a moisture level at or above the moisture threshold level can potentially damage the pump system's drive mechanisms or electronics, whereby an over-dosage or under-dosage could occur. As an alternative to automatically disabling the pump drive system, the process 400 can instead include an operation in which the user is prompt to confirm/approve that the pump drive system can be disabled. In addition to (or in as an alternative to) disabling the pump drive system, the controller device can initiate further user safety countermeasures as described in the next steps of operation process 400.

In operation 418, the controller device can emit an audible alarm in response to a determination of a moisture level at or above the threshold level. The purpose of the audible alarm is to alert the user to the issue that the pump system 10 is not operating normally and requires attention. The audible alarm can be emitted before, after, or simultaneously with the operation 416 of disabling the drive system.

Optionally, in operation 420, a separate light device of the pump system can be activated to provide a visible alarm (in addition to the audible alarm of operation 418). For example, the inspection light device 230 of pump system 10 can be activated to provide a visual notification to the user to the issue that the pump system 10 is not operating normally and requires attention.

In operation 422, the controller device can display a message to indicate that a moisture event was detected in response to a determination of a moisture level at or above the threshold level. For example, the user interface display screen 222 on the controller device 200 can display a short textual message to alert the user. The message can provide the user with an explanation of the reason for the audible and visual alarms. Further, the message can provide the user with an explanation that the pump drive system was automatically disabled.

In operation 424, the controller device can display a message prompting the user to remove the infusion set from the user's body. For example, the user interface display screen 222 on the controller device 200 can display the message prompting the user to remove the infusion set from the user's body. This message can be provided in order to assist the user with taking the proper actions to prevent an over dispensation of medicine to the user's body as a result of the detected high moisture level.

Optionally, in operation 426, the controller device can display a message prompting the user to detach the pump device from the controller device. For example, the user interface display screen 222 on the controller device 200 can display a message prompting the user to detach the pump device 100 from the controller device 200. In order to resume use of the pump system 10, the pump device 100 that has a moisture level at or above the moisture threshold level will need to be removed from the controller device 200 so that a new pump device, such as pump device 100′ (refer to FIGS. 4 and 5) can be coupled with the controller device 200. This message assists the user to take the proper actions in response to the activation of the moisture detection system, and to proceed towards resumption of the use of a properly functioning pump system 10.

Referring now to FIG. 11, some embodiments of a portable infusion pump system 700 having an ingress tube 784, a moisture detector 780, or both can employ a reusable pump apparatus (rather than a disposable pump device as previously described). In such circumstances, the infusion pump system 700 may comprise a reusable device that houses the control circuitry and the pump drive system within a single housing construct. In the particular embodiment depicted in FIG. 11, the pump system 700 comprises a reusable pump device that houses both the controller circuitry and the pump drive system. Similar to previously described embodiments, the pump system 700 can include a housing structure that defines a cavity in which a medicine cartridge can be received (not shown in FIG. 11; refer for example to cartridge 120 in FIG. 1). For example, the pump system 700 can be adapted to receive a medicine cartridge in the form of a carpule that is preloaded with insulin or another medicine. The pump drive system can act upon the fluid cartridge to controllably dispense medicine through an infusion set 146 and into the user's tissue or vasculature. In this embodiment, the user can wear the portable pump system 700 on the user's skin under clothing or in the user's pocket while receiving the medicine dispensed through the infusion set 146.

Similar to previously described embodiments, the infusion pump system 700 can be equipped with a structure that inhibits the ingress of liquids while also defining an open airflow path to provide air transmissibility with the surrounding environment. For example, the pump system 700 can house the aforementioned ingress tube 784 and (optionally) the moisture detector 780 that is a part of a moisture detection system. Similar to embodiments described in connection with FIG. 1, a first end of the ingress tube 784 is exposed to the ambient surroundings on the exterior of the housing for the pump system 700. A second end of the ingress tube 784 can be located within the housing for the pump system 700 and located adjacent to an absorbent element of the moisture detector 780. Using this arrangement, any liquid that flows into the housing for the pump system 700 through the ingress tube 784 will be absorbed by the absorbent element of the moisture detector 780 so that the liquid can be detected by the moisture detection system. Similar to embodiments described in connection with FIG. 1, the ingress tube 784 in this embodiment is an elongate tube with a central passageway that extends between first and second ends. The length of the ingress tube 784 may optionally be less than the length of the tube 384 described in connection with FIG. 1 (yet still greater than the lateral width of the tube 784). The length and diameter of the ingress tube 784 passageway can be configured to resist the transmission of liquids through the passageway while still allowing an extent of air to flow through the passageway. To accomplish this, the diameter of the ingress tube 784 can be selected in accordance with the teachings herein such that it is small enough to resist liquid transmissions while being large enough to allow some air transmission. In the example depicted in FIG. 11, the ingress tube 784 includes a restriction region that provides flattened passageway similar to the embodiment described in connection with FIGS. 8A-B.

Similar to previously described embodiments, the moisture detector 780 arranged in the housing of the pump system 700 can detect a moisture level greater than or equal to a moisture threshold level. The threshold level can be established below the moisture level that may cause the infusion pump system 700 to potentially fail or to cause an over-dosage or under-dosage of medicine to the user. Such a moisture level may occur, for example, by moisture seepage into the infusion pump system 700. Accordingly, the moisture detector 780 of the infusion pump system 700 can be constructed like any of the embodiments described above, such as the electrical resistance-type moisture sensor embodiment depicted in FIGS. 7 and 9. This type of moisture detection system may communicate with the control circuitry of the system 700 so that the infusion pump system 700 can initiate appropriate user safety countermeasures if the detected moisture level was greater than or equal to the predetermined threshold level.

In some embodiments, the moisture detector circuitry for use with the moisture detector 780 can be similar to the moisture detection system 379 described in connection with FIG. 9, but with several adaptations. For example, because the infusion pump system 700 has a single housing, the moisture detector circuit may not necessarily communicate via the electrical connectors 118 and 218. Consequently, the moisture detection circuit used with the moisture detector 780 in the infusion pump system 700 may optionally be a simplified version of the moisture detection system 379 depicted in FIG. 9.

Still referring to FIG. 11, the user interface 720 of the pump system 700 includes a display device 722 and one or more user-selectable buttons 724 a-e. The display device 722 can include an active area in which numerals, text, symbols, images, or a combination thereof can be displayed (as shown, for example, in FIG. 11). For example, the display device 722 can be used to communicate to the user that a moisture event has been detected and the drive system has been disabled (similar to the process described in reference to FIG. 10). Also, the display device 722 can be used to communicate a number of settings or menu options for the infusion pump system 700. For example, the display device 722 can be used to communicate medicinal delivery information 727, such as the basal delivery rate, a bolus dosage, a historical record of medicine delivered, the amount of medicine remaining in the cartridge, or the like. In another example, the display device 722 can be used to communicate time and date information, which can be used by the user to determine dosage schedules, bolus delivery times, meal times, or the like.

Accordingly, the user may press one or more of the buttons 724 a, 724 b, 724 c, 724 d, and 724 e to shuffle through a number of menus or program screens that show particular settings and data (e.g., review data that shows the medicine dispensing rate, the total amount of medicine dispensed in a given time period, the amount of medicine scheduled to be dispensed at a particular time or date, the approximate amount of medicine remaining in the cartridge 120, or the like). Also, the user can adjust the settings or otherwise program the pump system 700 by pressing one or more buttons 724 a, 724 b, 724 c, 724 d, and 724 e of the user interface 420. Thus, the user can contemporaneously monitor the operation of the pump system 700, including any messages pertaining to the moisture detection system from the same user interface 720.

A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims. 

What is claimed is:
 1. A portable infusion pump system, comprising: a portable housing defining a space to receive a medicine; a pump drive system positioned in the portable housing to dispense the medicine from the pump device when the medicine is received in the space of the portable housing; control circuitry configured to electrically communicate with the drive system to control dispensation of the medicine from the portable housing; a clearance hole formed in the exterior of the portable housing; and a channel extending through the portable housing that defines an open airflow passageway, the channel being in fluid communication with the clearance hole, an interior surface of the channel defining a narrowed restriction region having a reduced width that is less than a corresponding width of the open airflow passageway at another region, the restriction region dimensioned to inhibit ingress of liquid to an interior of the portable housing while allowing the channel to provide air pressure equilibrium between an exterior of the portable housing and the interior of the portable housing, wherein the narrowed restriction region of the channel is free of an occupying structure.
 2. The portable infusion pump system of claim 1, wherein the channel extends through the portable housing at a predetermined location, and wherein the channel is defined by a tube that engages into or slightly through the clearance hole.
 3. The portable infusion pump system of claim 1, comprising an ingress tube including the channel, the ingress tube positioned in the portable housing and having a longitudinal length that is greater than a lateral width of the ingress tube.
 4. The portable infusion pump system of claim 3, wherein the ingress tube is positioned in a hole defined by the portable housing, the open airflow passageway of the ingress tube being exposed to both an exterior of the portable housing and an interior of the portable housing.
 5. A portable infusion pump system, comprising: a portable housing defining a space to receive a medicine; a pump drive system positioned in the portable housing to dispense the medicine from the pump device when the medicine is received in the space of the portable housing; control circuitry configured to electrically communicate with the drive system to control dispensation of the medicine from the portable housing; and a channel extending through the portable housing that defines an open airflow passageway, the channel being in fluid communication with an opening in an exterior of the portable housing, an interior surface of the channel at least partially defining a narrowed restriction region having a reduced width that is less than a corresponding width of the open airflow passageway at another region, the restriction region dimensioned to inhibit ingress of liquid to an interior of the portable housing while allowing the channel to provide air pressure equilibrium between an exterior of the portable housing and the interior of the portable housing.
 6. The portable infusion pump system of claim 5, wherein the open airflow passageway includes a second restriction region.
 7. The portable infusion pump system of claim 5, wherein the reduced width of the first restriction region is about 10 to about 40 microns and the corresponding width of the open airflow passageway at the another region is about 0.1 to 1.5 millimeters.
 8. The portable infusion pump system of claim 1, further comprising a moisture detector positioned in the portable housing, wherein the moisture detector provides an indication that the moisture level in the portable housing is greater than or equal to a predetermined threshold level of moisture.
 9. The portable infusion pump system of claim 8, wherein an end of the open airflow passageway is positioned adjacent to an absorbent element of the moisture detector.
 10. The portable infusion pump system of claim 8, wherein when the moisture detector positioned in the portable housing is in electrical communication with the control circuitry, the control circuitry is configured to disable the pump drive system in response to the indication that the moisture level in the portable housing is greater than or equal to the predetermined threshold level of moisture.
 11. The portable infusion pump system of claim 4, wherein the portable housing comprises a controller device that houses the control circuitry and a pump device including a pump housing, the pump drive system positioned in the pump housing, and wherein the pump device is a one-time-use device equipped with one or more structures configured to prevent reuse of the pump device, wherein the pump housing includes an interior wall that defines a space to slidably receive an outer wall of a pre-filled medicine cartridge insertable through an opening defined by the pump housing, wherein the pump device further comprises a cap device that directly engages with the pump housing to enclose the pre-filled medicine cartridge in the pump housing when the pre-filled medicine cartridge is received in the space of the pump housing, and wherein the controller device is a reusable controller device including: a controller housing that is removably attachable to the pump housing in a fixed relationship; one or more electrical contacts disposed on the controller housing, the electrical contacts of the controller device being engageable with corresponding electrical contacts of the pump device when removably attached.
 12. A medical infusion pump system, comprising: a portable housing defining a space to receive a medicine; a pump drive system to dispense medicine from the portable housing when the medicine is received in the space; control circuitry that electrically communicates with the pump drive system to control dispensation of the medicine from the portable housing when the medicine is received in the space; and a liquid ingress resistance structure positioned in the portable housing and exposed to both an exterior of the portable housing and an interior of the portable housing, the liquid ingress resistance structure defining a predefined airflow passageway that provides air pressure equilibrium between the exterior of the portable housing and the interior of the portable housing and that inhibits ingress of water to the interior of the portable housing when the portable housing is submerged in water for a period of time, wherein the liquid ingress resistance structure comprises: a first portion exposed to the exterior of the portable housing; a second portion exposed to the interior of the portable housing; and a third portion positioned between the first portion and second portion, the third portion being narrowed to inhibit ingress of liquid from the first portion to the second portion; wherein the first, second, and third portions are defined by one or more inner surfaces of the liquid ingress resistance structure.
 13. The medical infusion pump system of claim 12, wherein the airflow passageway is free of an occupying structure.
 14. The medical infusion pump system of claim 12, wherein the liquid ingress structure positioned in the portable housing that defines the predefined airflow passageway comprises an ingress tube having a longitudinal length that is greater than a lateral width of the ingress tube, the predefined airflow passageway of the ingress tube being exposed to both an exterior of the portable housing and an interior of the portable housing.
 15. The medical infusion pump system of claim 14, wherein the ingress tube includes a region having a width between about 10 to about 40 microns.
 16. The medical infusion pump system of claim 13, wherein the pump system further comprises a moisture detector positioned in the portable housing, wherein the moisture detector provides an indication that the moisture level in the portable housing is greater than or equal to a predetermined threshold level of moisture.
 17. The medical infusion pump system of claim 16, wherein the liquid ingress resistance structure that defines the predefined airflow passageway is positioned adjacent to an absorbent element of the moisture detector.
 18. The medical infusion pump system of claim 16, wherein when the moisture detector positioned in the portable housing is in electrical communication with the control circuitry, the control circuitry is configured to disable the pump drive system in response to the indication that the moisture level in the portable housing is greater than or equal to the predetermined threshold level of moisture.
 19. The medical infusion pump system of claim 13, wherein the portable housing comprises a controller device housing the control circuitry that is removably attachable to pump housing that houses the pump drive system.
 20. The medical infusion pump system of claim 12, wherein the liquid ingress structure positioned in the portable housing that defines the predefined airflow passageway comprises an ingress tube. 